Target User:
Professional mechanics, technicians, and dedicated ATV enthusiasts.
Purpose:
To provide comprehensive repair and maintenance guidance for Kawasaki KLT110 and KLT160 ATVs.
Value Proposition:
Full factory information, detailed visuals, and unlimited lifetime access at a single purchase price.
Feature 1:
Authentic factory service data.
Feature 2:
Extensive diagnostic troubleshooting procedures.
Feature 3:
High-quality photographic and schematic illustrations.
Feature 4:
Lifetime digital access.
Primary Coverage:
Service, Repair, and Troubleshooting
Secondary Coverage:
Maintenance, Diagnostics, Reassembly
Estimated Page Count:
Hundreds (specific number not provided, but described as extensive)
Type:
Factory Service & Repair Workshop Manual
Language:
English (implied by product description and standard for US market manuals)
Format:
Digital Download (PDF)
Engine System:
Detailed disassembly, assembly, tuning, lubrication, cooling, fuel delivery, ignition, and exhaust systems.
Transmission Drivetrain:
Clutch operation, gearbox maintenance, differential service, drive shafts, and wheel hubs.
Suspension Steering:
Front and rear suspension component inspection, repair, and alignment; steering system diagnostics and overhaul.
Braking System:
Brake shoe/pad inspection and replacement, drum/disc service, hydraulic system bleeding, and cable adjustment.
Electrical System:
Wiring diagrams, battery service, charging system (stator, regulator/rectifier), lighting, ignition system components, and starter motor.
Chassis Bodywork:
Frame inspection, seat removal, fender and body panel maintenance, rack systems, and control lever adjustments.
Preventive Maintenance:
Routine checks, lubrication points, fluid changes, filter replacements, and general upkeep.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault finding trees.
Engine Repair:
Complete engine rebuild procedures, piston ring replacement, valve adjustments, cylinder head service.
Transmission Repair:
Gearbox overhaul, clutch component replacement, driveline maintenance.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and multimeter measurements.
Suspension Overhaul:
Replacement of worn suspension components, shocks, bushings, and steering linkages.
Depth:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds.
Detail Level:
Highly detailed with step-by-step instructions, critical torque specifications, and diagnostic parameters.
Visual Aids:
Hundreds of detailed photos and diagrams, including exploded views for component identification and assembly.
Engine Type Klt110:
4-stroke, SOHC, air-cooled
Engine Displacement Klt110:
110 cc (approx.)
Engine Type Klt160:
4-stroke, SOHC, air-cooled
Engine Displacement Klt160:
160 cc (approx.)
Horsepower Klt110:
Estimated 7-9 HP (typical for this class and era, exact figures not provided)
Torque Klt110:
Estimated 6-8 lb-ft (typical for this class and era, exact figures not provided)
Fuel Delivery:
Carburetor (specific model likely Mikuni, detailed in manual)
Fuel Type:
Unleaded gasoline
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Air-cooled
Transmission Type:
Automatic (likely CVT or semi-automatic with torque converter)
Drive System:
2WD (Rear Wheel Drive)
Gear Selection:
Forward, Neutral, Reverse (common on ATVs of this era)
Transmission Fluid:
Specific ATF or gear oil recommended in manual (e.g., SAE 80W-90 gear oil or specific automatic transmission fluid).
Length:
Approx. 70-75 inches (typical for the era, precise figures in manual)
Width:
Approx. 40-45 inches (typical for the era, precise figures in manual)
Height:
Approx. 40-45 inches (typical for the era, precise figures in manual)
Dry Weight:
Approx. 250-300 lbs (typical for the era, precise figures in manual)
Payload Capacity:
Likely around 150-200 lbs (typical for the era, precise figures in manual)
Front Tire Size:
Typically 22x8-10 or similar knobby ATV tires.
Rear Tire Size:
Typically 22x10-8 or similar knobby ATV tires.
Wheel Bolt Pattern:
Common 4-stud pattern (specific PCD would be in manual).
Safety Standards:
Adheres to industry safety standards for ATVs of its production era. No specific ratings like NHTSA or IIHS apply to this vehicle type.
Braking System:
Drum brakes front and rear (typical for the era, manual will specify exact configuration and drum sizes).
Parking Brake:
Hand-operated parking brake lever.
Operator Training:
Manual emphasizes the importance of operator training and safe riding practices.
Hand Guards:
Standard on handlebars for protection.
Oil Change Interval:
Typically every 1000-2000 miles or annually, specific interval provided in manual.
Spark Plug Replacement:
Recommended at regular intervals, tune-up frequency outlined in manual.
Air Filter Cleaning:
Frequent checks and cleaning recommended, especially in dusty conditions, as per manual.
Engine Oil Type:
API SE or SG, SAE 10W-40 or 20W-40 (specific viscosity may vary based on climate, refer to manual for exact recommendation).
Engine Oil Capacity:
Approximately 1.2-1.5 liters (exact capacity in manual).
Brake Fluid:
DOT 3 or DOT 4 (check manual for specific type, typically for hydraulic drum brake systems).
Carburetor Fouling:
Common with older ATVs due to fuel varnish. Manual provides cleaning and rebuilding instructions.
Suspension Wear:
Bushings and ball joints can wear over time. Manual details inspection and replacement procedures.
Electrical Connection Corrosion:
Especially in humid environments. Manual offers guidance on checking and cleaning electrical connectors.
Kawasaki Atv History:
Kawasaki has a long history in ATV manufacturing, with the KLT series being early pioneers in the utility ATV segment.
Klt Series:
The KLT series was known for its ruggedness and utility, paving the way for later models like the Bayou and Prairie.
Production Period:
1984-1985, indicating these are early models in the KLT lineup.
Manufacturing Location:
Likely Japan or USA (standard for Kawasaki production in that era, specific plant may be mentioned in manual).
